lower unit problems

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bigmitch

Recruit
Joined
Jan 25, 2004
Messages
2
I have a 96 model 25hp electric start johnson motor.There are four bolts holding the lower unit on.Two of these bolts are broken off.How hard is it to replace these bolts.Does anyone know where I cn find a diagram for the breakdown of the lower unit?
 
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alcan

Commander
Joined
Dec 14, 2001
Messages
2,505
Re: lower unit problems

Hi Bigmitch<br />Sounds like your faced with a few challenges. This sould be able to be repaired. I would strongly suggest that you obtain a manual first. This will give you the info you need.
 
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Cricket Too

Lieutenant Commander
Joined
May 14, 2003
Messages
1,732
Re: lower unit problems

Mitch welcome to the site. The hard part is not replacing the bolts it's getting the broken ones out. You're probably gonna have to drill them out, if you have a welder available some guys weld nuts to them and get them out that way. You can get a good breakdown of the lower unit in a service manual which is good to have for alot of things, you can buy one on this site. Good luck.
 
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Cricket Too

Lieutenant Commander
Joined
May 14, 2003
Messages
1,732
Re: lower unit problems

Mitch welcome to the site. The hard part is not replacing the bolts it's getting the broken ones out. You're probably gonna have to drill them out, if you have a welder available some guys weld nuts to them and get them out that way. You can get a good breakdown of the lower unit in a service manual which is good to have for alot of things, you can buy one on this site. Good luck.
 
OBJ

OBJ

Supreme Mariner
Joined
Dec 27, 2002
Messages
10,161
Re: lower unit problems

Hi Mitch...welcome to the forums.<br /><br />If there is a piece sticking out you can get hold of with vice grips, heat the outside (carefully) and see if they will come lose. Other than that, drill and tap.<br /><br />An OEM service manual will give you the break down on the gear case. Some generic manuals will to. OEM's available from any dealership. Generics available from iboats.<br /><br />Keep us posted....thanks.
 
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bigmitch

Recruit
Joined
Jan 25, 2004
Messages
2
Re: lower unit problems

Thank yall for all of your answers.The problem is I can,t get a hold of the bolts to weld or get a hold on them.Can I take the lower unit off and take them out this way?
 
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Solittle

Fleet Admiral
Joined
Apr 28, 2002
Messages
7,518
Re: lower unit problems

You should be able to drop the lower unit by removing the remaining bolts. That will make it easier to get at the two broken ones. check here for info on how to remove the broken ones:<br /><br /> http://www.outboardrepairs.com/bolts/
 
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